Bite sized refrigerated yogurt products

ABSTRACT

Refrigerated yogurt products of small size suitable for eating with the fingers are prepared by providing a frozen yogurt composition in individual serving portions and coating the frozen yogurt portions with a fat based coating that is a solid at 45° F., thereby completely enveloping the frozen yogurt portions. The coated frozen yogurt portion is allowed to thaw to form a refrigerated yogurt product and is stored at a temperature of from about 32° F. to about 45° F. The yogurt composition has a final viscosity of from about 35,000 to about 150,000 cP at 4° C., and has a total solids content of at least about 22% and/or exhibits a viscosity reduction at 45° F. of less than 10% after two freeze/thaw cycles. Methods and products are described.

REFERENCE TO RELATED APPLICATIONS

The present application represents a divisional application of U.S.patent application Ser. No. 13/112,149, filed May 20, 2011, which claimsthe benefit of priority under 35 U.S.C. 119(e)(1) of a U.S. ProvisionalPatent Application No. 61/346,585, filed May 20, 2010, which isincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to refrigerated yogurt products. Morespecifically, this invention relates to refrigerated yogurt products ofsmall size suitable for eating with the fingers.

BACKGROUND OF THE INVENTION

Fermented dairy products, such as yogurt, typically refer tocompositions produced by culturing (fermenting) one or more dairyingredients, also sometimes referred to as a dairy base, with abacterial culture that contains the lactic acid-producing bacteria, suchas Lactobacillus bulgaricus and/or Streptococcus thermophilus. Suchproducts are available in a wide variety of styles and formulations.

For example, U.S. Pat. No. 4,971,810 (Hoyda et al.) discloses fiberfortified yogurt products; U.S. Pat. No. 4,952,414 (Kaufman et al.)discloses yogurt with cereal pieces; U.S. Pat. No. 6,235,320 (Daravingaset al.) discloses multi-layered, colored yogurt products; U.S. Pat. No.7,033,634 (Engesser et al.) discloses aerated or whipped yogurt productsand describes that a hydrated emulsifier blend can be added to acultured yogurt post fermentation; U.S. Pub. No. 2005/0255192 (Chaudhryet al.) discloses a method for making cultured dairy products withdecreased fermentation times; and U.S. Patent Application titled “NOVELAERATED MILK COMPOSITIONS,” filed Feb. 1, 2006, by Ketchmark et al.,having Attorney Docket No. 6653US, and U.S. Ser. No. 11/324,550discloses aerated milk compositions such as yogurt.

Additionally, frozen yogurt products are available in the marketplacethat can be consumed with the hands, such as Yoplait parfait bitesproduct and various frozen yogurt novelties.

Consumers enjoy convenient, portable ways to eat healthful products suchas yogurt, without the need to use a spoon. An example of such a productis Go-GURT® Portable Lowfat Yogurt, which is a yogurt product providedin a tube for portable consumption. U.S. Patent Application PublicationNo. 2008/0089991 describes gelled food products such as yogurt orpudding products that are hand-holdable. These products contain ahydrocolloid ingredient that is present in an amount such that thegelled dairy composition has a Gel Strength Value of at least 100 grams.See claim 1 of the published application.

Confectionery products comprising a high water activity component suchas yogurt are described in U.S. Patent Application Publication No.2008/0050484. This application notes the problem of dissolution of themoisture sensitive confectionery materials by the high water activitycomponents, and states that this can be prevented by use of moisturebarriers. In the described method, the shell is first molded, a moisturebarrier is deposited onto the shell, and then the high water activitymaterial is deposited into the molded shell. See paragraphs[0030]-[0034]. An alternative enrobing process whereby the high wateractivity material is first formed into a desired shape and subsequentlyhermetically covered with at least one layer of low water activitymaterial is described. The application states that “[f]orming of thehigh water activity material may involve a set time, or cooling step inorder to give the material a consistency appropriate for cutting resp.enrobing and coating.” See paragraph [0044].

Patent application EP 1378174A1 describes a high water food product withan edible casing containing a moist filling, which is preferably ayogurt based filling. The described product is prepared by first formingthe casing, then pouring a liquid or viscous filling material into thecasing, and then sealing the casing. See paragraph [0019]. U.S. Pat. No.5,573,793 to Saintain describes a cookie or chocolate shell food producthaving a filling based on a dairy product. The filling is fermented andcontains live lactic acid bacteria. The filling has a water activity ofbetween 0.75 and 0.81.

There is a continuing need to provide new and improved yogurt products,especially having characteristics that are appealing to consumers.

SUMMARY OF THE INVENTION

A method is provided for preparing a refrigerated yogurt product ofsmall size suitable for eating with the fingers. In the method, a yogurtcomposition is provided in individual serving portions in the frozen orpartially frozen state. These individual serving portions are coatedwith a fat based coating that is a solid at 45° F., thereby completelyenveloping the frozen yogurt portions. The coated frozen yogurt portionsare allowed to thaw to form a refrigerated yogurt product and is storedat a temperature of from about 32° F. to about 45° F. In an embodiment,the yogurt composition of the refrigerated yogurt product has a totalsolids content of at least about 22% and a final apparent viscosity offrom about 35,000 to about 150,000 cP at 4° C. In another embodiment,the yogurt composition of the refrigerated yogurt product exhibits aviscosity reduction at 45° F. of less than 10% after two freeze/thawcycles.

In an embodiment of the present invention, a refrigerated yogurt productof small size suitable for eating with the fingers is provided. Thisrefrigerated yogurt product comprises a yogurt composition in a portionof from about 2 to about 12 grams, and more preferably from about 4 toabout 8 grams, that has been coated with at least one a fat basedcoating, thereby completely enveloping the yogurt portion. The yogurtcomposition of the refrigerated yogurt product has an apparent viscosityof from about 35,000 to about 150,000 cP at 4° C. and exhibits aviscosity reduction at 45° F. of less than 10% after two freeze/thawcycles. In another embodiment, the yogurt composition of therefrigerated yogurt product has a total solids content of at least about22%, and has an apparent viscosity of from about 35,000 to about 150,000cP at 4° C. In another embodiment, the yogurt composition of therefrigerated yogurt product has a total solids content of from about 22to about 30 percent and has an apparent viscosity of from about 35,000to about 150,000 cP at 4° C. The fat based coating is a solid at 45° F.;and the refrigerated yogurt product is stored at a temperature of fromabout 32° F. to about 45° F.

The present method and product provide the consumer with a convenient,portable way to eat yogurt without a spoon that affords a unique yogurtconsumption experience. The yogurt composition in the center of therefrigerated yogurt product is actual yogurt, meaning that it meets thestandard of identity of yogurt comprising live cultures. Additionally,the yogurt composition in the center of the refrigerated yogurt productcan have the expected consistency and mouthfeel of a yogurt. The centerof the product can be creamy and provide the expected viscosity of thetarget product, whether that can be an ordinary yogurt, a Greek styleyogurt, a strained or concentrated yogurt, a whipped yogurt, and soforth. In other examples, the center might be other fresh, cultureddairy product, such as fromage frais, quark or farmer's cheese.

The present invention solves the problem of manufacture of providingsmall size yogurt products that are suitable for eating with thefingers, wherein a true yogurt eating experience is provided by theproduct. By providing a yogurt composition that will survive freezecycles with minimal loss of viscosity, the final product achieves theunique desired organoleptic experience. In an embodiment of the presentinvention the yogurt product achieves the desired final organolepticproperties by the yogurt composition having a total solids content of atleast about 22%, where at least one third of the solids content is fromthe milk solids (protein, lactose, fat, ash), and preferably more thanhalf of the solids are from milk. In preferred embodiments, at least 10%of the solids content is from soluble solids (such as monosaccharides),and more preferably at least 14% of the solids content is from solublesolids. Yogurt compositions having a solids content of less than about22% have been observed to exhibit moisture migration failure, therebypossessing less than desirable shelf life.

In a preferred embodiment, the yogurt has a fat content of 1% to 6%.Non-fat filling and higher fat fillings may be used in alternativeembodiments. Yogurt compositions comprising at least some fat arepreferred for taste and texture. However, lower fat compositions arepreferred for better nutrition.

Additionally, the refrigerated yogurt product provides a uniqueorganoleptic experience by providing an outside coating layer thatcreates a solid shell consumption experience, with a creamy and/orliquid inside. In an embodiment of the present invention therefrigerated yogurt product delivers a crunchy outer shell consumptionexperience by incorporating particulate inclusions, such as granola, inor on the coating layer. The combination of particulate inclusions onthe outside along with a soft and creamy filling on the inside providesthe consumer a dual texture as well as the feeling of a hearty,satisfying snack. In another embodiment of the present invention therefrigerated yogurt product delivers a cracking outer shell consumptionexperience by use of a durable outer shell, such as a hard chocolate orfat coating layer.

The present refrigerated yogurt product provides organoleptic experiencethat is quite different from shelf stable yogurt snacks such as yogurtcovered raisins, yogurt filled grain bars, etc., because the presentproduct delivers the texture of yogurt (as otherwise must be served in acontainer) along with the health benefits of yogurt, giving consumers anew eating occasion.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this application, illustrate several aspects of the inventionand together with a description of the embodiments serve to explain theprinciples of the invention. A brief description of the drawings is asfollows:

FIG. 1 is a flowchart of a process for manufacture of the refrigeratedyogurt product of the present invention.

DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS

The embodiments of the present invention described below are notintended to be exhaustive or to limit the invention to the precise formsdisclosed in the following detailed description. Rather a purpose of theembodiments chosen and described is so that the appreciation andunderstanding by others skilled in the art of the principles andpractices of the present invention can be facilitated.

Turning now to FIG. 1, an embodiment of the process for manufacture ofthe refrigerated yogurt product of the present invention is shown as aflowchart. In the first step 10, a yogurt composition is prepared.

As used herein, the term “yogurt” includes, but is not limited to, allof those food products meeting the definition as set forth in the U.S.Food and Drug Administration Code of Federal Regulations (CPR) Title 21Section 131.200, 131.203, and 131.206.

In general, the yogurt can be made from a fermentable dairy base andbacterial culture. In addition, a yogurt composition may include agel-forming hydrocolloid component and, optionally, one or moreadditives.

Dairy bases for making a yogurt are well known and are described in,e.g., U.S. Pat. No. 4,971,810 (Hoyda et al.); U.S. Pat. No. 5,820,903(Fleury et al.); U.S. Pat. No. 6,235,320 (Daravingas et al.); U.S. Pat.No. 6,399,122 (Vandeweghe et al.); U.S. Pat. No. 6,740,344 (Murphy etal.); and U.S. Pub. No. 2005/0255192 (Chaudhry et al.). In general, adairy base includes at least one fermentable dairy ingredient. Afermentable dairy ingredient can include raw milk or a combination ofwhole milk, skim milk, condensed milk, dry milk (for example, dry milksolids non-fat, or MSNF). Preferably, the fermentable dairy ingredientis composed of bovine milk. However, if desired other milks can be usedas a partial or whole substitute for bovine milk such as camel, goat,sheep or equine milk. The fermentable dairy ingredient may also comprisegrade A whey cream, and/or such other milk fraction ingredients asbuttermilk, whey, lactose, lactalbumins, lactoglobulins, or wheymodified by partial or complete removal of lactose and/or minerals,and/or other dairy ingredients to increase the nonfat solids content,which are blended to provide the desired fat and solids content. Ifdesired, the dairy base can include a filled milk component, such as amilk ingredient having a portion supplied by a non-milk ingredient (forexample, oil or soybean milk).

In exemplary embodiments, a yogurt composition of the refrigeratedyogurt product has a fat content in the range of from 0 to 12 weightpercent based on the total weight of the yogurt composition. Withrespect to exemplary embodiments of the refrigerated yogurt product, thefat content is in the range of from 0.5 to 10 weight percent, preferablyfrom 0.5 to 5 weight percent, from 0.5 to 3 weight percent, and evenmore preferably about 1% weight percent based on the total weight of theyogurt composition.

In embodiments of the present invention, the refrigerated yogurt producthas a total solids content of at least about 22% and a milk solidscontent of greater than 38 weight percent based on total solids content,and has fat content of from about 0.5% to about 3% and soluble solidscontent (sucrose and lactose) of from about 9 to about 13%. In anembodiment, the yogurt composition of the refrigerated yogurt productcomprises from about 50% to about 80% milk solids. This formula isfermented and used without a concentration step.

In another embodiment of the present invention, the refrigerated yogurtproduct has a total solids content of from about 24% to about 35%, withmilk solids being from about 50 to 70% of the total solids, solublesolids content of from about 7 to about 11%, and fat content of fromabout 1 to about 4%. This formula is also fermented and used without aconcentration step.

In another embodiment of the present invention, the yogurt is preparedand fermented, with a subsequent concentration step after fermentation.In an embodiment, a finished filling (after concentration step) isprovided with total solids content of from about 40 to about 60%, withmilk solids being from about 30 to about 50% of the total solids, fatcontent of from about 1 to about 3% and the soluble solids of from about10 to about 14%.

In addition, dairy bases typically include sweeteners, flavoringredient(s), process viscosity modifier(s), vitamin(s) nutrient(s),combinations of these, and the like. Other ingredients that may beincluded are gel-forming additives, stabilizers, sequestrants, etc.

Examples of suitable sweeteners include one or more nutritivecarbohydrate sweetening agents. Exemplary nutritive sweetening agentsinclude, but are not limited to, sucrose, liquid sucrose, high fructosecom syrup, dextrose, liquid dextrose, various DE com syrups, com syrupsolids, beet or cane sugar, invert sugar (in paste or syrup form), brownsugar, refiner's syrup, molasses, fructose, fructose syrup, maltose,maltose syrup, dried maltose syrup, malt extract, dried malt extract,malt syrup, dried malt syrup, honey, maple sugar, and mixtures thereof.In some embodiments, particularly in low fat and/or low calorievariations, the dairy base can comprise a high potency non-nutritivecarbohydrate sweetening agent. Exemplary high potency sweetening agentsinclude aspartame, sucralose, acesulfame potassium, saccharin,cyclamates, thaumatin, tagatose, rebaudioside, stevia, and mixturesthereof. In exemplary embodiments, the sweetener is typically present inan amount of from 0 to 20 weight percent, preferably 12 to 17 weightpercent based on the total weight of the yogurt composition.

In exemplary embodiments, a process viscosity modifier can be present inan amount of from 0.5 to 3 weight percent, preferably 1 to 2 weightpercent based on the total weight of the yogurt composition. Anexemplary process viscosity modifier can be commercially obtained fromNational Starch (Bridgewater, N.J.) under the tradename THERMTEX®. Inembodiments of the present invention, the yogurt can contain 0 to 3%starch, 0 to 1% gelatin, and 0 to 0.5% LM pectin. An example of asuitable gelatin is 220 bloom. An exemplary non-dairy, gel-forminghydrocolloid ingredient for use in the present invention can includegelatin, agar, alginate, carrageenan, pectin, starch, xanthan/locustbean gum blend, gellan gum, konjac gum, combinations of these, and thelike. It is noted that some gel-forming hydrocolloid ingredients (e.g.,starch) can have structural modifications that can influence thegel-forming ability of other hydrocolloids. Examples of usefulstabilizers and thickeners such as starch, gelatin, pectin, agar,carrageenan, gellan gum, xanthan gum, carboxy methyl cellulose (CMC),sodium alginate, hydroxy propyl, methyl cellulose, and mixtures thereof.In some embodiments, the dairy base can comprise a bovine, porcine, orpiscine gelatin. A bovine gelatin in the range of about 200 to about 250bloom strength can be used; also, Type B bovine gelatin in the range ofabout 220 to about 230 bloom strength is suitable.

When included, stabilizers or thickeners can be included in an amountsufficient to provide a desired viscosity to the yogurt composition,such that the yogurt composition can be processed (e.g., pumped) throughequipment during formulation of the inventive compositions.Additionally, stabilizers can be provided to assist in providingfreeze/thaw stability to the yogurt.

Any bacterial culture useful in making yogurt compositions forconsumption can be used with the dairy base composition. Such bacterialculture(s) are live and active and are well known. An exemplarybacterial culture can include any microorganism suitable for lacticfermentation such as Lactobacillus sp., Streptococcus sp., combinationsof these, and the like. More specifically, a bacterial culture caninclude Lactobacillus delbrueckii subspecies bulgaricus, Streptococcusthermophilus, Streptococcus salivarius ssp thermophilus, Lactobacilluslactis, Lactobacillus casei, Lactobacillus acidophilus, Bifidobacteriumlactis, Bifodobacterium bifidus, Lactococcus cremoris, Lactococcuslactis, Lactococcus lactis ss diacetylactis, combinations of these, andthe like. A variety of synonyms exist for the term “bacterial culture.”These synonyms include, for example, live culture, active culture, liveand active culture, starter culture, and the like.

The yogurt composition is formulated so that the composition of thefinal refrigerated yogurt product has a viscosity of from about 35,000to about 150,000 cP at 4° C. In an embodiment of the present invention,the final viscosity of the yogurt composition of the refrigerated yogurtproduct is from about 60,000 to about 120,000 cP at 4° C. In embodimentsof the present invention, the yogurt composition may be a whipped orgelled yogurt, provided that the yogurt is sufficiently stabilized tomaintain its texture once frozen and thawed.

In embodiments of the present invention, the yogurt composition has a pHin the range of about 4.35 to about 4.85, preferably from about 4.5 toabout 4.7, and most preferably about 4.60.

Optionally, the yogurt composition can further include a variety ofadjuvant materials to modify the nutritional, organoleptic, flavor,color, or other properties of the composition. For example, the yogurtcomposition can additionally include synthetic and/or naturalflavorings, and/or coloring agents can be used in the compositions ofthe invention. Any flavors typically included in yogurt compositions canbe used in accordance with the teachings of the invention. Also, flavormaterials and particulates, such as fruit and fruit extracts, nuts,chips, and the like, can be added to the yogurt compositions as desired.The flavoring agents can be used in amounts in the range of about 0.01to about 3%. Coloring agents can be used in amounts in the range ofabout 0.01 to 0.2% (all percentages based upon total weight of theyogurt composition).

When included, fruit and fruit extracts (e.g., sauces or purees) cancomprise about 1% to about 40%, preferably from about 5% to 15% of theyogurt composition. The fruit component can be admixed with theemulsifier prior to addition to the first dairy base, or can be added asa separate component, as desired.

The thus provided yogurt composition is frozen in freezing step 20,whereby the temperature of the yogurt composition is lowered to a levelsufficient to thicken the yogurt composition so that it retains itsshape in an unsupported manner for a time sufficient to be coated.Preferably, the temperature of the yogurt composition is lowered to atemperature of from about −10° F. to −15° F. The yogurt composition canbe frozen in any appropriate manner, such as holding batches of yogurtat a temperature below 32° F., such as a temperature of from about −40°F. to about 10° F., and preferably from about −35° F. to about −20° F.Optionally, the yogurt composition can be frozen in a continuous processby pumping through a cooling array so that the temperature of the yogurtis lowered to a level sufficient to thicken the yogurt composition asdescribed above. In an embodiment of the present invention, the frozenyogurt composition has a consistency at the time of coating much likesoft serve ice cream or, in another embodiment, much line regular “hardpack” ice cream.

The frozen yogurt composition is portioned in a portion forming step 30.Preferably, the portions are sized for individual servings, and morepreferably are sized for individual “bite sized” portions. In anembodiment, the frozen yogurt portions are from about 2 to about 6grams. In another embodiment, the portions are sized for individualservings as “multiple bite” portions. Examples of this embodimentprovide frozen yogurt portions in sizes of from about 6 to about 25grams.

The frozen yogurt portions may be of any appropriate shape, such as agenerally spherical shape or a generally cylindrical shape. It has beenfound that rounded shapes are preferable, because such shapes facilitateeven coating of the coating composition to completely envelop the yogurtportion. Thus, while for example cubic shapes are envisioned as anembodiment of the present invention, the sharp edges and comers of sucha product present added challenges in making a coated yogurt productwithout defects in the coating that permit leakage of the yogurt. In anembodiment of the present invention, the frozen yogurt portions rangefrom about 1 cm to about 4 cm diameter. The 1 cm diameter frozen yogurtportions would be considered to be very small, and would thereforeprovide very small volume or “payload” of yogurt. The 4 cm diameterfrozen yogurt portions would be considered to be very large as anindividual bite-size snack, and would likely require more than one biteto eat the product. In a preferred embodiment, the frozen yogurt portionhas a half sphere shape with a diameter of from about 2.0 to about 3.0cm diameter and having a height of from about 1.0 to about 2.0 cm. Aparticularly preferred size is a sphere with a diameter of from about2.0 to about 2.5 cm.

In an embodiment of the present invention the yogurt composition isformed into pieces of a size appropriate to be consumed in multiplebites. Examples of this embodiment include pieces formed into elongatedshapes, such as a stick or a bar. Such an embodiment would have across-sectional shape of a circle, oval, octagon, rectangle, etc, havinga diameter or width of from about 1 to about 4 cm, and a lengthappropriate to provide the total serving size, such as from about 6 toabout 15 cm. In an embodiment, the frozen yogurt portions are from about2 to about 12 grams.

The yogurt portions may be formed in any suitable manner, for example byshaping the frozen yogurt composition or by extrusion of the frozenyogurt directly out of the freezing unit and separating the yogurtextrudate into individual serving portions.

Optionally, the order of freezing step 20 and portion forming step 30are reversed or occur simultaneously. Thus, in an embodiment of thepresent process, the yogurt portions may be formed by depositing theunfrozen yogurt or partially frozen yogurt in a mold and freezing theyogurt sufficiently for the yogurt to maintain its shape for coatingpurposes. If the yogurt is unfrozen at the time that it is placed in themold, it will conform to the shape of the mold. Thus, the mold may havefor example a generally half-spherical shape or a generallyhalf-cylindrical shape, which shape will be reflected in the shape ofthe yogurt composition. In embodiments wherein the yogurt is partiallyfrozen, a portion of the yogurt composition may be manipulated duringthe further freezing process, e.g. by being deposited on a moving beltand allowed to roll, to provide the desired shape. The yogurt may befrozen by any appropriate technique, such as by direct contact (e.g.dropping pieces into liquid nitrogen bath or blast freezer with coldair, or indirect contact (e.g. through shelf freezer). Direct contact ispreferable, because it is faster freezing, forming smaller ice crystals.

The formed portions of the yogurt composition are then coated in coatingstep 40.

The coating properties optimally lead to minimal drip time, shortsetting time, and good adherence to the yogurt center without cracks orother discontinuous areas in the coating. The set time should be shortenough for efficient manufacture, but long enough to allow the granolaparticles on the exterior to be applied before the coating solidifies.The coating also needs to provide a firm structure, which will bothprotect the thawed center and allow the product to be neatly consumedwith one's hands. Finally, the coating should provide a pleasant tasteand non-greasy texture in the mouth.

The coating composition for coating the frozen yogurt portion preferablyis a fat based coating made mostly out of hydrogenated fat so it issolid at room temperature. The coating serves to encase the yogurtfilling. Preferably, the coating composition is formulated to keep anyparticulate inclusions in the coating, such as granola, crunchy. To keepthe particulate inclusions crunchy, the coating compositions typicallyare made almost entirely of fat based ingredients (due to low wateractivity). The fat based coating would preferably be based on blends oflauric fats (such as coconut oil, palm kernel oil or fractionatedcoconut or palm kernel oil) and non-lauric fats, (such as cocoa butter,partially hydrogenated vegetable oil (from soybean, palm, cottonseed orrapeseed) or fractionated oils). The partially hydrogenated oils havethe disadvantage of high trans fatty acid content, and therefore thefractionated oils are preferred for the non-lauric fat component. Theoptimum blend will have the desired brittleness provided by the lauriccomponent, and the needed elasticity provided by the non-lauriccomponent. Optionally, lower fat coatings may be used if it is notcrucial to keep the outer coating/particulates crunchy or if theparticulate is itself fat based. The coating can be made of variousingredients and levels of fat as long as it can be heated to form aliquid, is solid at refrigerated temperatures and can completely encasethe yogurt. Typical coating composition will be from 30-35% fat and 40to 50% sugar. Flavor can optionally be added to the coating. In anembodiment of the present invention, the coating is made from chocolate.A typical dark sweet chocolate coating would contain 35-40% chocolateliquor, 40-45% sugar, and 35-40% fat, while a typical milk chocolatecoating would contain 10% liquor, 10% milk solids, 45-55% sugar, and30-40% fat.

A preferred coating comprises coconut oil and palm kernel oil in a ratiofor from about 60/40 to about 80/20, and more preferably at a ratio ofabout 70/30. Coatings prepared outside of this range are less preferreddue to processing and performance challenges. For example, when theratio of coconut oil to palm kernel oil is higher than 80/20, thecoating sets too slowly for optimal production processes. When the ratioof coconut oil to palm kernel oil is lower than 60/40, the resultingcoating tends to crack, and also sets so quickly that there isn't timefor enough external particle inclusions such as granola to stick.

In an embodiment of the present invention, the coating consists of fat,sugar, flavoring and an emulsifier. The fat content will be a mixture ofliquid and solid fat. Solid fat content can be, for example, partiallyhydrogenated coconut oil, palm oil, fractionated palm oil,interesterified palm oil, cocoa butter, or other solid vegetable fats.Liquid fat content can be, for example, coconut oil, fractionatedcoconut oil, fractionated palm oil, or other vegetable oils. Preferably,the coating composition comprises 30-35% fat. Preferably the coating iscompletely liquid above 120° F., yet solidifies quickly (less than 3seconds) after coating onto the frozen yogurt portion. In an embodimentof the present invention, the fat based coating comprises 20-80% of fatthat is liquid at 72° F. and 20-80% of fat that is solid at 72° F. Thefat based coating preferably exhibits an initial peak force value of 8.5to 11.5 kg and a maximum peak force value of 9.5 to 14kg, at 4° C. Thepeak force value for the finished, coated piece itself preferably rangesfrom 1 to 5 kg at 4° C. The fat coating preferably has crystalline meltcharacteristics of being completely liquid at 30 to 35° C., as measuredby DSC. In embodiments with more coconut oil, the onset of melting wasat 30° C., but increased to 35° C. with higher palm kernel oil content.Optionally, the first coating may comprise particulate inclusions.Preferably, the first coating does not comprise particulate inclusionsbecause such particulate inclusions may weaken the integrity of thecoating, thereby leading to leakage of yogurt from the product afterthawing, or to prevent migration of moisture through the coatingcomposition. Thus, preferably the first coating composition is free ofany visibly detectable undissolved particulate inclusions, including,for example granola pieces or even cocoa powder.

The coating composition is applied to the frozen yogurt portion by anyappropriate technique, such as by dipping the portion in the coatingcomposition or spraying, brushing, or otherwise applying the coatingcomposition to the frozen yogurt portion. Preferably, the coating isapplied to form a layer that is from about 1.0 to about 1.5 mm thick.Preferably the coating completely seals the yogurt portion so thatyogurt cannot leak out of the final product after thawing. For a yogurtportion that is about 2 cm in diameter and 6 g, the first coat will addabout 2 g of weight to the portion, the second coat will add about 5 gmore, and the granola will add another 1.5 g.

The coated yogurt composition preferably is coated a second time inoptional second coating step 50. The application of a second coating ispreferred to provide further integrity and strength to the final productto prevent leakage of yogurt from the product after thawing.

In an embodiment, the second coating composition comprises particulateinclusions, such as pieces of granola, nuts, cookies, grain basedparticulates (such as cereal, graham, etc), chocolate, hard candy,seeds, toffee, caramel, fruit and the like and mixtures thereof. Inaddition, other nutrients and additives can be incorporated with theparticulates for added health benefits.

Preferably, the second coating is applied to form a layer that is fromabout 1 to about 3 mm thick. In an embodiment of the present invention,the second coating comprises particulate inclusions and is applied toform a layer that is from about 2 to about 3 mm thick, and preferablyfrom about 2 to about 2.5 mm thick.

In an embodiment, the refrigerated yogurt product comprises the abovedescribed components in the following percentages by weight: 35-45%yogurt composition, 10-20% first coat, 35-45% second coat and 5-15%particulate inclusions.

It is preferable not to freeze the yogurt portion (i.e. the center ofthe product) again after the first coating, but to store themrefrigerated or to apply a second coat right away. If the centers arerefrozen after the first coating, the expansion due to freezing may leadto very small cracks that can disrupt the integrity of the moisturebarrier.

For better adhesion of the particulate inclusions and to provide moreparticulate inclusions on product surface, some of the particulateinclusions are stirred in to the second coating prior to dipping thefrozen yogurt portion. When the frozen yogurt portion is dipped in thecoating, the coating cools and thus begins to solidify. Generally, thecoating is mostly solid by the time the yogurt portion is completelycoated in particulate inclusions.

Optionally, additional particulates can be added to the outside of theouter coating of the yogurt product by applying particulate inclusionsas described above to the unhardened coating material, e.g. by dredgingthe coated yogurt portion in the particulate inclusions.

The particulate inclusions on the outer surface of the refrigeratedyogurt product in particular provide the product with a unique dualtexture, as well as facilitating the status of the product as a “fingerfood” by keeping the consumers fingers dry. Larger particulates can beadded to the coating composition itself as part of the second orsubsequent coating composition, but the outer particulate coating ispreferably of a finer grind for complete coverage of the product.Optionally, different particulates and coating compositions can beapplied sequentially to the yogurt product to provide further flavor andtexture experiences.

A preferred refrigerated yogurt product of the present inventioncomprises from about 3 to 7 grams of yogurt and has a firstfat-containing coating of from about 1 to about 3 grams, a secondfat-containing coating of from about 3 to 7 grams (including particulateinclusions), and an additional outer layer of particulate inclusions offrom about 1 to about 3 grams.

The coated yogurt composition is then allowed to thaw (while stored atrefrigeration temperature) and is stored at refrigeration temperature inthaw step 60.

The thus prepared product is package for distribution in bulk, inmultiple serving packages or as individual product. In an embodiment,the yogurt product is maintained in the frozen state for shipping withinstructions for allowing the product to thaw at the point of purchaseor consumption and for storage at refrigeration temperatures. Transportand storage in a “wholesale” environment in the frozen state providesadvantages in product stability for handling purposes and potentialshelf life benefits for an optimal freshness experience at the time ofconsumption.

EXAMPLES

Representative embodiments of the present invention will now bedescribed with reference to the following examples that illustrate theprinciples and practice of the present invention.

A. Yogurt Preparation.

The yogurt compositions of the present refrigerated yogurt product arecreated following this general process:

Milk and other ingredients are blended to mix and hydrate any powders.Then the blend is heated to 160° F., homogenized at 1000 psi, heated to195° F., held for 9 minutes, and cooled to 110° F. Yogurt culture(Streptococcus thermophilus and Lactobacillus bulgaricus) is added, aswell as any adjunct cultures (such as Lactobacillus acidophilus,Bifidobacterium bifidus, etc.), and product is fermented until the pHdrops from the natural pH of the milk (about 6.5) to about pH 4.5.Product is then cooled. For strained yogurt, the finished product isseparated by mechanical means (centrifugal separator or ultrafiltration)to concentrate the product before it is completely cooled afterfermentation.

Representative yogurt compositions are as follows:

An embodiment of the present refrigerated yogurt product has a totalsolids content of at about 25% and a milk solids content of 41 weightpercent based on total solids content and has fat content of 1% andsoluble solids content (sucrose and lactose) of 11.5%. The compositionadditionally comprises starch (3%), gelatin (0.7%) and low methoxypectin (.3%). This formula is fermented and used without a concentrationstep.

In an embodiment of the present invention, the refrigerated yogurtproduct has a total solids content of 31.5%, with a milk solids contentof 57% of the total solids, and soluble solids content of 9%, fatcontent of 3%. This formula is also fermented and used without aconcentration step.

In a third embodiment, yogurt is prepared and then concentrated afterfermentation. This leads to a finished filling (after concentration stephaving a total solids content of 48%. The milk solids are 37% of thetotal solids, fat content is 2% and the soluble solids are 12%.

B. Sample Preparation.

Balls or dollops of yogurt having a weight of about 6 grams are placedonto aluminum foil and are frozen to a temperature so that the frozenyogurt portions will retain their shape in an unsupported manner.

A fat based coating composition consisting of 50% sugar, 35% coconut oiland 15% palm kernel oil is heated to 150 F, so that the coatingcomposition is in liquid form. The frozen yogurt portion is dipped intothe coating composition to completely coat the portion. The firstcoating is allowed to set, and a second coating as described below isapplied. Preferably, this second coating is applied almost immediatelyafter application of the first coating, which is particularly beneficialin commercial scale production. Alternatively, solidification of thefirst coating is assisted by chilling the coating such as by placing thecoated article in a refrigerator for 5-10 minutes.

A second coating composition is prepared by grinding a granolacomposition (preferably Cascadian Farms™ Oat & Honey Granola) in foodprocessing machine (Cuisinart™ type machine for two 10 second pulses.Separate grinds on a #8 mesh screen (about one third will be retained onscreen). Heat fat based coating composition as above and blend thegranola pieces retained on the #8 screen into the coating (22% byweight).

The single coated frozen yogurt portion is dipped into second coatingcomposition to completely coat the single coated frozen yogurt portion.The product is then quickly removed and immediately put into paper boatwith finely ground granola, and completely coated in granola. The thuscoated product is placed on a tray and stored in a refrigerator.

C. Testing Protocol.

Viscosity

Unless otherwise indicated (e.g. by designation of temperature), allviscosities are apparent viscosities measured at 25° C. using aBrookfield viscometer with a No. 5 spindle for 25 seconds at 10 rpm.

Coating Hardness

Hardness measurements were made at 4° C. Single pieces were compressedbetween parallel plates until the coating fractured. The maximum forcerequired to fracture the coatings was recorded in kg units.

All patents, patent applications, and publications cited herein areincorporated by reference as if individually incorporated. Unlessotherwise indicated, all parts and percentages are by weight and allmolecular weights are weight average molecular weights. The foregoingdetailed description has been given for clarity of understanding only.No unnecessary limitations are to be understood therefrom. The inventionis not limited to the exact details shown and described, for variationsobvious to one skilled in the art will be included within the inventiondefined by the claims.

What is claimed is:
 1. A refrigerated yogurt product of small sizesuitable for eating with the fingers, comprising: a yogurt compositionin an individual serving portion coated with a fat based coating that isa solid at 45° F., thereby completely enveloping the yogurt portion; theyogurt composition product having either: i) a total solids content ofat least about 22% and a viscosity of from about 35,000 to about 150,000cP at 4° C.; or ii) a viscosity of from about 35,000 to about 150,000 cPat 4° C. and exhibiting a viscosity reduction at 45° F. of less than 10%after two freeze/thaw cycles.
 2. The product of claim 1, wherein theviscosity of the refrigerated yogurt product is from about 60,000 toabout 120,000 cP at 4° C.
 3. The product of claim 1, further comprisinga second fat based coating.
 4. The product of claim 3, wherein thesecond fat based coating comprises particulate inclusions.
 5. Theproduct of claim 4, wherein the particulate inclusions are selected fromthe group consisting of pieces of granola, nuts, cookies, grain basedparticulates, chocolate, hard candy, seeds, toffee, caramel, fruit andmixtures thereof.
 6. The product of claim 1, wherein the fat basedcoating is from about 1.0 to about 1.5 mm thick.
 7. The product of claim1, wherein the yogurt composition has a total solids content of fromabout 24% to about 35%.
 8. The product of claim 1, wherein the yogurtcomposition comprises at least about 38% milk solids based on totalsolids content.
 9. The product of claim 1, wherein the yogurtcomposition of the refrigerated yogurt product comprises from about 50%to about 80% milk solids based on total solids content.
 10. The productof claim 1, wherein the fat based coating comprises 20-80% of fat thatis liquid at 72° F. and 20-80% of fat that is solid at 72° F.
 11. Theproduct of claim 1, wherein the fat based coating has crystalline meltcharacteristics of being completely liquid at 30° C. to 35° C., asmeasured by DSC.
 12. The product of claim 1, wherein the fat basedcoating has a hardness of from about 9.5 to about 14 kg peak force at 4°C.
 13. The product of claim 1, wherein the refrigerated yogurt producthas a shape selected from a generally spherical shape, a generallycylindrical shape, a generally half-spherical shape, and a generallyhalf-cylindrical shape.
 14. The product of claim 1, wherein theindividual serving portion is from about 2 to about 12 grams.